Shanghai Royal Technology Inc. is One of the top PVD vacuum coating machine manufacturers in the worldwide.We are specialize in PVD (Physical Vapor Deposition) and PECVD thin-film deposition technology and offer a range of superior coatings and equipment for various industries.
Royal Technology provides a complete line of vacuum deposition systems optimized for depositing thin film materials on complex three-dimensional substrates
We also specialize in advanced batch PVD coaters (RTEP- thermal evaporation, RTAC-cathodic arc coater, RTSP- magnetron sputtering coater, RTAS- arc+sputtering models) and ( R2R web vacuum metallizer )roll-to-roll processes that require precision deposition, tension, and uniformity. Additionally, we offer equipment and technology specifically designed for medical instrumentation and bio-compatible coatings except decorative coatings.
Product Description:
R2R (Roll-to-Roll) web aluminum vacuum metallizers are machines used in the manufacturing industry for depositing a thin layer of aluminum onto flexible substrates in a continuous roll-to-roll process. This process is commonly employed for various industrial purposes, such as packaging, electronics, automotive, and decorative applications.
The R2R web aluminum vacuum metallizer typically consists of several key components, such as an unwind station, cleaning section, pre-treatment section, metallization chamber, cooling section, and winding station. The unwind station is where the substrate material roll enters the machine, and the winding station is where the metallized substrate is wound onto a roll once the metallization process is complete.
The metallization chamber is the heart of the machine, and it usually exists in a vacuum environment. This is where the aluminum deposition takes place, and where a series of evaporation sources or cathodes are used to heat the aluminum material until it reaches its evaporation point, forming a thin, uniform layer on the substrate. After this process, the substrate is passed through a cooling section before being wound onto a roll.
The advantages of R2R web aluminum vacuum metallizers are many, including high production speeds, excellent control over the thickness and uniformity of the aluminum layer, and the ability to process a wide range of flexible substrates. Therefore, the machines are essential for creating functional and decorative coatings on materials e.g. plastic films, paper, foils, and textiles.
It should be noted that the exact specifics and features of R2R web aluminum vacuum metallizers may depend on the manufacturer and the intended application.
WEB COATERS FOR PACKAGING INDUSTRY
Aluminum decorative coated plastic film and paper are essential in packaging applications. Royal Technology has developed some of the latest technologies that have higher productivity and lower operational costs. The new coating process avoids the heavy aluminum foil laminating, moreover, the heavy barrier (up to ONE micron thickness) metallized web is stronger and more resistant to moisture and oxidization.
| Description | R2R Web Vacuum Metallizer Models | |||||
| R2R-600 | R2R-1250 | R2R-1350 | R2R-1650 | R2R-2200 | R2R-2500 | |
| Coating Technology | Thermal or Sputtering | Thermal Evaporation | ||||
| Substrate width (Max.)mm | 600 | 1100 | 1250 | 1500 | 2200 | 2500 |
| Roll Diameter (Max.)mm | 800 | 1000 | 1000 | 1000 | 1000 | 1000 |
| Core Diameter(inner)mm | 3"/6" | 6" | ||||
| Coating speed (meter/second) | 0.5 ~17, adjustable, depends on coating process required | |||||
| Coating Rollers Temperature (℃) | -20 to 25 | |||||
| Coating Chamber Ultimate Pressure(Pa) | 5*10-3 | |||||
| Pumping Speed | At the condition of without loading, clean, room temperature: less than 8 mins, from atm to 7*10-2 | |||||
| Pre-treatment Tool | Linear Ion Source | |||||
| Deposition Source | BN Crucible or Planar/Rotary cylinder sputtering cathode | |||||
| Deposition Material | Al, Al,Cr,Cu,Ni, NiCr, Stainless Steel, Ti, | |||||
| Working Environment | Power:3Phase, 5wires, 380V±10%,50Hz/60Hz | |||||
| Cooling water: EDI, 4~6 Bar @25℃ | ||||||
| Compressed air: 5~6Bar, filtered and dried | ||||||
The RT-R2R Web Aluminum Vacuum Metallizer features high throughput, high vacuum and film and paper metallization. High throughput reduces production costs and heavy deposition layers ensure high barrier applications, while the free-span process eliminates the drum line and edge trim.
This metallizer is friendly operation for low tension substrates such as CPP, BOPP, and LDPE, with individual wire feeds and easy maintenance. It features precision web handling mechanisms with servo motor drives for precise control at any line speed.
Last but not least, the RT-R2R Web Aluminum Vacuum Metallizer is designed with a compact layout for easy installation, and requires minimal floor space.
R2R (Roll-to-Roll) web vacuum metallizing is a process of depositing a thin layer of metal, typically aluminum, onto a flexible substrate in a continuous roll-to-roll manner. It is a versatile and widely used technique in industries such as packaging, electronics, automotive, and more with advantages such as high production speeds, precise control over coating thickness, excellent adhesion, and the ability to process a wide range of flexible substrates. The process consists of the following steps:
1. Substrate Unwinding: The process begins with a roll of the flexible substrate material, which is unwound and fed into the metallizing machine.
2. Cleaning and Pre-Treatment: The substrate may pass through a cleaning section to remove any surface contaminants that could affect the adhesion of the metal coating. Following cleaning, the substrate may undergo pre-treatment processes such as corona treatment or primer application to enhance the bonding between the substrate and the metal layer.
3. Metallization Chamber: The heart of the R2R web vacuum metallizing equipment is the metallization chamber. The substrate enters the chamber, which is maintained at a high vacuum. The chamber typically consists of a series of evaporation sources or cathodes, which contain the metal (such as aluminum) to be deposited.
4. Metal Evaporation: The metal within the evaporation sources is heated to its evaporation point. As the metal evaporates, it forms a vapor cloud within the chamber. The vaporized metal atoms travel in straight lines and condense onto the moving substrate, forming a thin, uniform metal layer.
5. Substrate Cooling: After the metallization process, the coated substrate passes through a cooling section, where the metal layer solidifies and stabilizes.
6. Substrate Winding: Finally, the metallized substrate is wound onto a roll, ready for further processing or use in various applications.
It's worth noting that the specific details and parameters of the R2R web vacuum metallizing process can vary depending on factors such as the desired metal coating, substrate material, and intended application. The process can be optimized to control factors like coating thickness, adhesion, and uniformity to meet specific requirements.
· Strong vacuum system with holding Pump.
· New design evaporator system (staggered and top clip boats )for high evaporation rate and excellent uniformity,wire feeding one side.
· Programmable controller (SIEMENS PLC) with automatic process start / stop + Touch Screen
· Cooling and heating unit for deep cooling (and reheating) of the coating drum to avoid thermal damage of the substrates up to minus 15°
· Winding system adopt advance three rolls and three motors constant tension system, Contain 3 groups independence Siemens AC motor ;
· Fault diagnostic system.
· One set Cold trap System for coating chamber.
· One set Cold trap System for winding chamber.
CCTV to monitor the web roll rewinding and unwinding working
Vacuum web (or roll) coating is a process of coating a thin, flexible material (web) that comes in the form of a roll of material. This roll of material of various widths, lengths, and weights is unwound, coated, and rewound in a continuous operation in a vacuum system, at a speed that can reach up to 2000~3000fpm (feet-per-minute).
R2R (Roll-to-Roll) web vacuum metallizing equipment has numerous applications in various industries. It can be used to create metallic finishes on plastic components for decorative purposes in industries like automotive, electronics, appliances, and consumer goods. The same equipment is also employed for reflecting properties in mirrors, reflective films, and lighting fixtures, production of conductive coatings for touchscreens, and EMI/RFI shielding in electronics. Additionally, vacuum metallizing is also used in the production of solar energy systems to enhance sunlight reflectivity and increase energy capture. Finally, it is utilized as a security measure for banknotes, labels, and packaging as the reflective and visually distinctive characteristics of metallized coatings make them difficult to counterfeit. This wide-ranging possibilities in terms of functional and decorative coatings on flexible substrates has made R2R web vacuum metallizing equipment a must-have across industries
We provide a range of technical support and service options for our Roll To Roll Coating Machine to ensure you get the most out of your machine. Our team of experienced technicians is available to provide:
We strive to ensure that our customers get the best out of our Roll To Roll Coating Machine by providing high-quality and timely technical support and service.
